Ok, I've been reading all the posts here (and at the other place) and I have to say one thing. So far everyone (besides Drano) has told you to focus on the DMD controller, but you mention in your first post the issue goes away when you pull a battery which is located on the MPU. Now I will say that pulling a battery should have ZERO effect on this issue in that the batteries have nothing to do with the DMD or the controller. That being said, logic would dictate that the forces of pulling the battery on the MPU is re-connecting whatever contacts are having issues and fixing your DMD issue. Where the MPU sends the DMD controller PCB all of the display info via the ribbon cables, I would absolutely start with pulling each ribbon cable off and re-seating a couple of times starting at the MPU, and working your way through the game all the way over to the DMD controller. If that doesn't seem to correct the issue, I would honestly start looking for cold solder joints on the back of the MPU, as well as get a PLCC chip puller and remove and re-seat the ASIC on the MPU.
Do not rebuild any PCB at this point, there are no signs that your HV is failing.
Where this is an intermittent issue, my $$ is on either of the 3 things listed above. Do the above and report back.
D